AU649872B2 - Polypropylene resin and its composition - Google Patents

Description

OPI DATE 25/01/93 AOJP DATE 25/03/93 APPLN. ID 21666/92 j PTNUMBER PCT/JP9Z/00807 1 III111111N 1111111111111111111111111111 AU9221 666 (51) 5 (11) ffl miIPV WO 93100375 C08F 210/06, C08L 23/14 Al (43) M j U1 1993fF 170(O7.0 I1. 1993) (21) MWAV rCT/JP92/ooao7 (74){ifAA (22) MrAWME 199MJ6Ji2513(25. 06. 92) 4F)M± ~M04 2 (WATANAlE. K ihea) T 10 t W 1 T 0f 1 4 ff6- 4,1 '?Wruttf 9 W %Alutr- P Tokyo. CJP) 01I4 3/183 2 57 19 9 146A 2 78(2 7. 06. 91) JP 0lJ13/183 6 29 19 9 1 6) 28 l(2 8. 06. 91) Jp (81) jaumI *ZSF3/183630 19914F6fl288(28, 06, 91) jp ATcMjfl~), AU. BE(~affl). CA. CHCf*' 1).

OJAF3/183631 1991d4V6)l288C28. 06. 91) JP DECMAJ~f), DK(M~i*I1). ES CW'lO)d.~ FUCWHWT), #*AF3/183633 1991AF6iJ28E(28. 06, 91) jp GB (Wfl*I), OR(M)Wq), ITc tiq~I). KR, 009&P13/183634 1991&F6,92813(28. 06. 91) JP LUcftiff), MCCRA10), NLC0ti*4w). SE c49T).

US.

CIDENITSJ PETROCHEMICAL CO., LTD.)CJI'/JP) e TjI100J 1r11 Tokyo, UP)2 (72) A 99y~ Z XY 614, [ACTANAKA. Ak ir a)(CJP/JP) rPJII WI4NAXAGANVA, Masaru)tJP/JP) Hideo)(JP/JP) 9q*A(h1IYAZAXI. Sue to)[JP/JP3 09i1tCTA1CARAZAKI, Tat suya)(JP/JP) Title :POLYPROPYLENE RESIN AND ITS COMPOSITION a Weight fraction b Temp.

c position of principal elution peak d half-value width Tuna x c (57) Abstract A polypropylene resin which has very high rigidity, heat resistance and impact resistance, is well balanced among these properties, and is characterized in that: the content of a-olefin units other than propylene is 4 mole 0/ or less, the mmmm fraction in the pentad fraction of the propylene polymer is 96.0 or above as determined by '3C-NMR spectroscopy, the position (Tmnax) of the principal elution peak of the propylene polymer is 118.0 'C and the half-value width of that peak is less than 4.0 degrees as determined by the programmed temperature fractionation method, the intrinsic viscosity [711 of the propylene polymer ranges from 0.5 to 5.0 dl/g, and the rubber component content exceeds 25 as measured by the pulse NMR method.

V

POLYPROPYLENE BASED RESINS AND THEIR COMPOSITIONS Field of the Invention The present invention relates to a polypropylene based resin having extremely high stiffness, good heat resistance and high impact strength and a resin domposition comprising the resin.

Further, the present invention relates to a polypropylene resin having high stiffness and good heat resistance as well as having good dimensional stability resulting in prevention of warping or deformation of the resulting product.

Further, the present invention relates to a polypropylene resin which exhibits high stiffness and high impact strength and thus is useful in a wide variety of fields such as automotive, electrical appliances or the like.

Furthermore, the present invention provides a less expensive polypropylene resin having high stiffness and high impact strength and high melt tension, and a resin composition comprising the resin.

Related Art In general, polymers prepared from homopolymerization or copolymerization of propylene in a first stage and random copolymerization of propylene and the other alpha-olefin in a second stage, are called propylene block copolymers. These block copolymers are drastically improved in low temperature impact strength without substantially sacrificing good properties of polypropylene, high stiffness and good heat resistance.

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Heretofore, propylene block copolymers are produced by a method which comprises subjecting propylene to homopolymerization or copolymerization in the presence of a high stereoregular catalyst in the former polymerization step in a homopolymerization vessel, and then subjecting propylene and the other alpha-olefin to random copolymerization in the presence of the homopolymer or copolymer obtained as above in the latter polymerization step in a random copolymerization vessel.

As mentioned above, in the presence of a highly stereoregular catalyst, propylene/olefin copolymerization is carried out one after another to improve impact strength.

However, as the copolymerized portions increase, the stiffness decreases. Good balance of stiffness and impact strength has not been sufficiently achieved.

In the meanwhile, techniques to improve impact strength of a propylene block copolymer is known (Japanese Patent Application Publication Nos. 23565/1991 and 26203/1991). Either of these techniques improves stereoregularity of the propylene homopolymers. However, the improvement is still within the prior art level, and improvement in stiffness and heat resistance is not sufficient.

Further, according to the technique disclosed in Japanese Patent Application Laid-Open No. 187043/1984, the resultant polymers have extremely poor impact strength when compared with a polymer having the same amount of copolymerized portion since formulation control of the copolymerized portion is not sufficient. Thus, it cannot be said that balance of stiffness and impact strength is sufficient.

The present invention was made in view of the above situations, and has its object of providing a polypropylene based resin having extremely high stiffness, good heat resistance and high impact strength.

Further, in the field of injection-molding using a polypropylene resin, in order to improve stiffness and heat 2 resistance of the resin itself, it is generally conducted to broaden molecular weight distribution by way of a multi-stage polymerization or the other methods, and then keeping molecular orientation in the molding stage. However, in this method, after molding the product suffers large shrinkage and anisotropy.

Particularly, in the case of producing precise parts and large products, a problem readily occurs due to warping or deformation of the products, or poor engagement of the molded products. It is desired to overcome these problems.

On the other hand, to improve the above-mentioned molding shrinkage, it is adapted to narrows molecular weight distribution of a polypropylene resin by way of decomposition using peroxide. However, this method has a problem in that decrease in mechanical and physical properties such as stiffness and heat resistance is substantial to extent that the decrease cannot be ignored. Thus, this method does not provide substantial improvement.

The present invention was made in view of the above situations, and has another object of providing a polypropylene resin having excellent stiffness and heat resistance as well as having good dimensional stability, capable of preventing warping or deformation of the products due to shrinkage derived from molecule orientation during the injection-molding, and thus useful as industrial materials in several fields.

Further, a polypropylene resin alone is not sufficient in stiffness and heat resistance. Thus, fiber reinforced polypropylene resins filled with glass fibers or the 2ike or filler containing polypropylene resins having high heat resistance are used as industrial materials for various parts for automotive (including interior materials), parts for electrical appliances and the like.

On the contrary, to improve stiffness and heat resistance of a polypropylene resins, it is proposed to improve pentad fraction (mmmm fraction) measured by NMR (Japanese Patent 3 Application Publication No. 33047/1990). However, such improvement alone is not sufficient, although it is can be used as a reference for improvement in stiffness, since the mmmm fraction measured by NMR merely indicates consecutive five isotactic fractions.

Further, in this technique, certain effects can be expected if a process capable of separating isotactic components such as solvent polymerization is used. However, this technique cannot be applicable to a process such as gas phase polymerization in which a whole amount of the Lesultant polymer become the final product. It was actually confirned that meritorious effects could not be obtained from a such process.

Further, improvement only to the pentad fraction measured by NMR can be achieved by, for example, drastically changing the polymerization temperature or further adding an electron donor. However, such process drastically reduces productivity and thus is not cost effective.

As mentioned above, improvement to the pentad fraction measured by NMR has been made to improve stiffness and heat resistance of polypropylene. However, improvement only to the pentad fraction cannot give sufficient stiffness and heat resistance. Thus, it is desired to improve these properties.

The present invention was made in view of the above situations, and has another object of providing a polypropylene resin which has extremely high stiffness and heat resistance, and thus can be used, as it is, as industrial mdterials for various' parts for automotive, electrical appliances and the like.

Further, polypropylene resins, particularly those having low melt index (MI) have been used as plastics materials for sheets, films or the like.

It is desired to provide a technique to improve stiffness and heat resistance of a polypropylene resin in the extrusion molding techniques for low MI grade polypropylene sheets or films.

4 Further, in multi-stage polymerization, it is desired to improve productivity and cost performance since the multi-stage polymerization is necessarily used to obtain sufficient melt tension in the low MI grade area.

On the contrary, it is proposed to improve the pentad fraction measured by NMR and boiling heptane soluble fraction (II) to improve stiffness and heat resistance of a polypropylene resin (Japanese Patent Application Publication No. 30605/1991). However, such improvement alone is not sufficient although the pentad fraction or the boiling heptane soluble fraction can be used as a reference for improvement in stiffness and heat resistance.

Further, the conventional techniques requiring multi-stage polymerization (Japanese Patent Applications Laid-Open Nos. 284252/1988 and 317505/1988) have a problem in that there are many restrictions on process or cost effectiveness and stereoregularity and the molecular weight distribution may broaden due to combination of polymerization steps under different conditions.

In other words, the resultant polymers have good average stereoregularity and molecular weight, but should have small amount of components having poor stereoregularity and having a low molecular weight, resulting in unsolved quality problems (particularly in gas phase polymerization).

The present invention was made in view of the above situations, and has another object of providing a less expensive polypropylene resin having extremely high stiffness, good heat resistance and high melt tension.

Disclosure of the Invention In order to achieve the above objects, the present invention provides a oooel polypropylene-based polymer resin comprising: S 25 a propylene polymer having a content of alpha-olefin other than propylene of from zero to not ~more than 4 mole percent, (ii) a pentad fraction (mmmm fraction) measured by 13C-NMR of at "least 96.0 percent, (iii) a main elution fraction peak position of at least 117.00C and a peak half value width of less than 4.0, these values being measured by the temperature raising separation method, and 6 (iv) an intrinsic viscosity of at least 0.5 du/g, but not more than 5.0 dl/g; and, a rubber content measured by pulse NMR of at least 8 percent.

00 I embodiment of the present invention provides a polypropylene based resin characterized by comprising: a propylene polymer having a content of alpha-olefin other than propylene of not more than 4 mole percent, and the following properties and a pentad fraction (mmmm fraction) measured by 13C-NMR of not less than 96.0 percent, a main elution fraction peak position of not less than 118.0 0 C and a peak half value width of less than 4.0, these values being measured by the temperature raising separation method, and an intrinsic viscosity of not less than 0.5 dl/g, but not more than 5.0 dl/g; and, a rubber content measured by pulse NMR of more than percent.

The first embodiment of the present invention will be described in more detail. First, each property will be described in detail.

Content of Alpha-olefin Other Than Propylene: The polypropylene based resins according to the present S^ropi\<e~e pe\yor-v cCrcc\v\ \r>Q invention comprlseAnot more than 4 mole percent, preferably 0 to 2 mole percent of alpha-olefin other than propylene, i.e., ethylene and/or alpha-olefins having at least 4 carbon atoms. If the content of alpha-olefin other than propylene exceeds 4 mole percent, the stiffness and heat resistance of the resultant polymers will be insufficient.

The polypropylene based resin according to the present invention contain a propylene copolymer having the following properties and Pentad Fraction (mmmm Fraction) As used herein, the "pentad fraction (mmmm fraction)" means a value measured by 13

C-NMR.

The propylene copolymers contained in the polypropylene based resins according to the present invention comprise a pentad S- 7 fraction measured by 1 3 C-NMR of at least 96.0 percent, preferably at least 97.0 percent, more preferably at least 97.5 percent. If the pentad fraction is less than 96.0 percent, the stiffness and the heat resistance of the resultant polymers will be insufficient.

Main Elution Peak Position and Peak Half Value Width Measured By the Temperature Raising Separation Method: These values can be measured by introducing a sample solution into a column to make the sample solution adsorbed to a filler, raising the column temperature and detecting concentration of the polymer solution eluted at each temperature.

As used herein, "Main Elution Peak Position (Tmax)" and "Peak Half Value Width are values defined by an analysis chart as shown in Fig. i. In other words, the main elution peak position means the peak position (temperature) when the biggest peak appears. The peak half value width means the peak width at a position where the height of peak is half of the biggest peak.

Stereoregularity of a polymer depends on elution temperature. Thus, stereoregularity distribution of a polymer can be evaluated by measuring the relation between the elution temperature and the polymer concentration by the temperature raising separation method.

The propylene polymers contained in the polypropylene based resins according to the present invention, have a main elution peak position of at least 118.0C, preferably at least 118.5 0 C, more preferably at least 119.0 0 C. Further, the peak half value width is less than 4.0, preferably less than 3.8, more preferably less than 3.4. If the main elution peak position is less than i18.0 0 C, the stiffness and heat strength of the resultant polymer will be decreased. Further, if the peak half value width is 4.0 or more, the stiffness and heat resistance of the resultant polymer will be also insufficient.

Intrinsic Viscosity -8- As used herein, the "Intrinsic Viscosity" means a value measured in decalin at 135 0

C.

The propylene polymers contained in the polypropylene based resins according to the present invention have an intrinsic viscosity of 0.5 to 5.0 dl/g, preferably 0.9 to 5.0 dl/g, more preferably 1.0 to 5.0 dl/g. If the intrinsic viscosity is less than 0.5 dl/g, the impact strength of the resultant polymer will be insufficient. If the intrinsic viscosity exceeds 5.0 dl/g, the moldability of the resultant polymer will be poor.

Rubber Component Content: As used herein, the "Rubber Component Content" means a value obtained from the Pulse NMR analysis made under the following conditions.

Analysis: In accordance with the techniques by Nishi et al (K.

Fujimoto, T. Nishi and R. Kado, Polym. 3.448(1972)), FID (Free Induced Decrease) is separated into three components showing different 1H spin-glide relaxation time (T2H). Then, among these three components, a component having the longest T2H is regarded as a rubber component, and the content of such fraction is defined as rubber component content.

The polypropylene based resin according to the present invention have a rubber component content measured by the Pulse NMR of more than 25 percent, preferably 30 to 70 percent, more preferably 30 to 60 percent. If the rubber component content is percent or less, the Izod impact strength of the resultant polymer will be decreased as shown in Fig. 2.

A process for producing the polypropylene based resin, according to the present invention, having the above-mentioned properties is not particularly limited. However, it is preferable to use polymerization catalysts which exhibit high polymerization activity and stereoregularity.

These polymerization catalysts and a process for producing polyolefins using the polymerization catalysts are -9disclosed in, for example, Japanese Patent Application No.

413883/1990 previously filed by the present applicant.

The polymerization catalysts disclosed in Japanese Patent Application No. 413883/1990 are characterized by using as a carrier a solid product prepared by the reaction of metallic magnesium, alcohol and a specific amount of halogen.

The polymerization is carried out in the presence of a solid catalyst component prepared using the solid product and a titanium compound and if desired an electron donor compound an organometallic compound and if desired an electron donor compound The solid products are prepared from metallic magnesium, alcohol, and halogen and/or a halogen-containing compound.

In this case, the metallic magnesium may be in any form, such as granule, ribbon, and powder. Also, the metallic magnesium may preferably be those free of magnesium oxide film covering the surface, although no specific restrictions are placed on its surface state.

The alcohol is not specifically limited; but it should preferably be a lower alcohol having 1-6 carbon atoms. Ethanol is particularly desirable, because it gives a solid product which greatly improves the catalyst performance. The alcohol may have any purity and water content. It is desirable, however, that the water content should be 1% or lower, preferably 2000 ppm or lower, because excess water in the alcohol forms magnesium hydroxide [Mg(OH)2] on the surface of metallic magnesium.

Moreover, the water content should preferably be as low as possible, usually 200 ppm or lower, so that the resulting magnesium compound has a good morphology.

The halogen is not particularly limited to, but includes chlorine, bromine and iodine with iodine being particularly preferred.

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1VT S The halogen-containing compounds are not particularly limited to, but include those having a halogen atom in the chemical formula. In this case the halogens are not particularly limited to, but include chlorine, bromine and iodine. In addition, among the halogen-containing compounds, halogen-containing metal compounds are particularly desirable.

Examples of the halogen-containing compounds which can preferably used, are MgCl2, MgI2, Mg(OEt)Cl, Mg(OEt)I, MgBr2, CaCl2, NaCl and KBr. Of these compounds, MgC12 and MgI2 are particular:j desirable.

The halogen-containing compounds may be used in any form and state, and may have any particle size. For example, it may be used in the form of solution in an alcohol type solvent such as ethanol.

The amount of the alcohol is not specifically limited; however, it usually ranges from 2 to 100 moles, preferably from to 50 moles, per 1 mole of the metallic magnesium. Use of an excess amount of alcohol may give reduced yield of a magnesium compound having a good morphology. With too small amount of alcohol, it is difficult to carry out smooth stirring in a reaction vessel. However, the above-mentioned molar ratio is not limitative.

The amount of halogen used ranges Lt least 0.0001 gram-atom, preferably at least 0.0005 gram-atom, more preferably at least 0.001 gram-atom, per 1 gram-atom of metallic magnesium.

The halogen-containing compounds should be used in an amount of at least 0.0001 gram-atom, preferably at least 0.0005 gram-atom, most preferably at least 0.001 gram-atom, per 1 gram-atom of the metallic magnesium. The use of the amount less than 0.0001 gram-atom cannot be distinguished from the use of halogen as a reaction initiator. Also, in order to obtain solid products having desired particle size, grinding or classification treatment of the magnesium compound is indispensable.

11 In the present invention, the halogen or the halogen-containing compounds can be used alone or in any combination. In addition, the halogen and the halogen-containing compound can be used together. In the case of using the halogen and the halogen-containing compound together, the total halogen atom amount ranges at least 0.0001 gram-atom, preferably at least 0.0005 gram-atom, more preferably at least 0.01 gram-atom, per 1 gram-atom of metallic magnesium.

The amount of the halogen or the halogen-containing compounds has no upper limit and can be appropriately selected within a range wherein the desired solid product is obtained. In general, an adequate amount of the total halogen atom content is less than 0.06 gram-atom, per 1 gram-atom cf metallic magnesium.

In addition, it is possible to freely control the particle size of the resulting solid catalyst by selecting an appropriate amount of the halogen and/or the halogen-containing compound.

The reaction of metallic magnesium, alcohol, and halogen and/or a halogen-containing compound may be carried out by any known methods, for example, a method of reacting metall 4 magnesium, alcohol, and halogen and/or a halogen-containing compound under refluxing conditions (at about 79 0 C) until the reaction system does not evolve hydrogen gas any longer (usually to 30 hours), to obtain a solid product. More specificallj.

such known methods (in the case of using an iodine-containing compound as a halogen-containing compound) include: a method which comprises adding an iodine-containing compound in solid form to a mixture of alcohol and metallic magnesium, and reacting them under heat-refluxing conditions; a method which comprises adding an alcohol solution of an iodine-containing compound dropwise to a mixture of alcohol and metallic magnesium, and reacting them under heat-refluxing conditions; and a method which comprises adding an alcohol solution of an iodine-containing

S

12 compound dropwise to a mixture of alcohol an, etallic magnesium while heating the mixture.

Regardless of the method selected, the reaction should preferably be carried out in an inert gas atmosphere such as nitrogen and argon and, if necessary, in the presence of an inert o ganic solvent such as saturated hydrocarbons such as n-hexane.

It is not necessary to place the metallic magnesium, alcohol, and halogen and/or a halogen-containing compound all at once in the reaction vessel. It is possible to place them by portions in the reaction vessel. It is desirable to place all of the alcohol in the reaction vessel at the beginning and then to add metallic magnesium by portions several times. This procedure prevents the reaction system from evolving hydrogen gas in a large amount at one time and hence ensures safety and permits the use of a smaller reaction vessel, without the partial loss of alcohol and halogen an/or a halogen-containing compound by splashing. The number of portions should be properly determined according to the size of the reaction vessel; but it is usually to 10 to avoid unnecessary complexity.

The reaction may be carried out batchwise or continuously. There is a modified method which comprises repeating the steps of adding a small portion of metallic magnesium to alcohol whose whole amount is first placed in a reaction vessel and removing the reaction product.

The thus obtained reaction product may be used for the synthesis of the next solid catalyst component after being subjected to drying or after being subjected to filtration and washing with an inert solvent such as heptane. The obtained solid product can be used as such in the following step without necessity of grinding or classification to obtain desired particle size distribution.

The solid product is almost spherical and has a sharp particle size distribution, with individual particles varying very little in sphericity. In this case, the solid 13 4,.

.Ai,4 product may preferably be composed of particles which have a sphericity of smaller than 1.60, preferauly smaller than 1.40 as defined by the following Formula S (El/E2) 2 (1) wherein El denotes the projected perimeter of a particle, and E2 denotes the perimeter of the circle of equal projected area of a particle, and a particle size distribution index of smaller than 5.0, preferably smaller than 4.0 as defined by the following Formula P D 90

/D

10 (2) wherein D90 denotes the particle diameter corresponding to a cumulative weight fraction of 90 percent. In other words, the cumulative sum of the weight of particles small,.r than the particle diameter defined by D9 0 accounts for 90 percent of the total weight of all the particles. D 10 is defined in the same way.

The titanium compounds used in the above-mentioned solid catalyst component may be represented by, for example, the following formula: TiXln(ORl)4-n wherein X 1 is a halogen atom, particularly a chlorine atom; R 1 is a hydrocarbon group having 1 to 10 carbon atoms, particularly a straight or branched alkyl group; if there are more than two R 1 they may be the same as or different from each other; and n is an integer of 0 to 4.

More specifically, these titanium compounds include Ti(O-i-C3H 7 Ti(O-C4H 9 4 TiCl(O-C2H5)3, TiCl(O-i-C3H7)3, TiCl(O-C4H 9 3 TiC12(O-C 4 H9) 2 TiC12(O-i-C 3 H7)2 and TiC14.

14 ~4, In the above-mentioned solid catalyst component if desired, any electron donor compounds can be used. The electron donor compounds usually include organic compounds containing an oxygen atom, nitrogen atom, phosphorus atom or sulphur atom. Examples of such compounds are amines, amides, ketones, nitriles, phosphines, phosmylamides, esters, ethers, thioethers, alcohols, thioesters, acid anhydrides, acid halides, aldehydes, organic acids and organosilicon compounds containing a Si-O-C linkage.

More specifically, examples of the electron donor compounds are aromatic carboxylic acids such as benzoic acid and p-oxybenzoic acid; acid anhydrides such as succinic anhydride, benzoic anhydride and p-toluic anhydride; ketones having 3 to 15 carbon atoms such as acetone, methyl ethyl ketone, methyl isobutyl ketone, acetophenone, benzophenone and benzoquinone; aldehydes having 2 to 15 carbon atoms such as acetaldehyde, propionaldehyde, octyl aldehyde, benzaldehyde and naphthaldehyde; esters having 2 to 18 carbon atoms such as methyl formate, ethyl formate, methyl acetate, ethyl acetate, vinyl acetate, propyl acetate, octyl acetate, cyclohexyl acetate, ethyl propionate, methyl butyrate, ethyl butyrate, ethyl valerate, methyl chloroacetate, ethyl dichloroacetate, methyl methacrylate, ethyl crotonate, ethyl pivalate, dimethyl maleate, ethyl cyclohexanecarboxylate, methyl benzoate, ethyl benzoate, propyl benzoate, butyl benzoate, octyl benzoate, cyclohexyl benzoate, phenyl benzoate, benzyl benzoate, methyl toluate, ethyl toluate, amyl toluate, ethyl ethylbenzoate, methyl anisate, ethyl anisate, ethyl ethoxybenzoate, ethyl p-butoxybenzoate, ethyl o-chlorobenzoate, ethyl naphthoate, gamma-butyrolactone, 8-valerolactone, coumarin, phthalide and ethylene carbonate; mono- and di-esters of aromatic dicarboxylic acids, especially mono- and and di-esters of phthalic acid, such as T R 15 Lf z 1* monomethyl phthalate, dimethyl phthalate, monomethyl terephthalate, dimethyl terephthalate, monoethyl phthalate, diethyl phthalate, monoethyl terephthalate, diethyl terephthalate, monopropyl phthalate, dipropyl phthalate, monopropyl terephthalate, dipropyl terephthalate, monobutyl phthalate, dibutyl phthalate, monobutyl terephthalate, dibutyl terephthalate, monoisobutyl phthalate, diisobutyl phthalate, monoamyl phthalate, diamyl phthalate, monoisoamyl phthalate, diisoamyl phthalate, ethyl butyl phthalate, ethyl isobutyl phthalate and ethyl propyl phthalate; and acid halides having 2-20 carbon atoms, wherein the acid portion (acy group portion) is preferably an aliphatic (including those having a ring such as alicyclic) mono-, di- or trivalent acyl group having 2 to carbon atoms (a hydroxyl group is withdrawn from a mono-, di- or tribasic acid), or an aromatic (including alkaryl and aralkyl) mono-, di- or trivalent acyl group having 7 to 20 carbon atoms (a hydroxyl group is withdrawn from a mono-, di- or tribasic acid), and the halogen is preferably chlorine or bromine, particularly chlorine.

In the present invention, acid halides which can be preferably used include, for example, acetyl chloride, acetyl bromide, propionyl chloride, butyryl chloride, isobutyryl chloride, 2-methylpropionyl chloride, valeryl chloride, isovaleryl chloride, hexanoyl chloride, methylhexanoyl chloride, 2-ethylhexanoyl chloride, octanoyl chloride, decanoyl chloride, undecanoyl chloride, hexadecanoyl chloride, octadecanoyl chloride, benzylcarbonyl chloride, cyclohexanecarbonyl chloride, malonyl dichloride, succinyl dichloride, pentanedioyl dichloride, hexanedioyl dichloride, cyclohexanedicarbonyl dichloride, benzoyl chloride, benzoyl bromide, methylbenzoyl chloride, phthaloyl chloride, isophthaloyl chloride, terephthaloyl chloride and benzene-l,2,4-tricarbonyl chloride. Of these compounds, phthaloyl chloride, isophthaloyl chloride and terephthaloyl chloride are particularly preferable. Phthaloyl chloride is most 16 preferable. In addition, these acid halides may be used alone or in combination with one another.

The electron donor compounds further include ethers having 2 to 20 carbon atoms such as methyl ether, ethyl ether, isopropyl ether, n-butyl ether, amyl ether, tetrahydrofuran, anisole, diphenyl ether, ethylene glycol butyl ether; acid amides such as acetic acid amide, benzoic acid amide and toluic acid amide; amines such as tributyl amine, N,N'-dimethylpiperazine, tribenzylamine, aniline, pyridine, pycoline, tetramethyl ethylene diamine; nitriles such as acetonitrile, benzonitrile, tolunitrile; tetramethyl urea; nitro benzene; lithium butyrate; organosilicon compounds having a Si-O-C linkage such as trimethylmethoxysilane, trimethylethoxysilane, dimethyldimethoxysilane, dimethyldiethoxysilane, diphenyldimethoxysilane, methylphenyldimethoxysilane, diphenyldiethoxysilane, phenyltrimethoxysilane, gamma-chloropropyltrimethoxysilane, methyltriethoxysilane, ethyltriethoxysilane, vinyltriethoxysilane, butyltriethoxysilane, phenyltriethoxysilane, gamma-aminopropyltriethoxysilane, chlorotriethoxysilane, ethyltriisopropoxysilane, vinyltributhoxysilane, isopropylcyclohexyldimethoxysilane, isobutylcyclohexyldimethoxysilane, tert-butylcyclohexyldimethoxysilane, isopropylcyclohexyldiethoxysilane, isobutylcyclohexyldiethoxysilane, tert-butylcyclohexyldiethoxysilane, methylcyclohexyldimethoxysilane, ethyl silicate, butyl silicate, trimethylphenoxysilane, methyltriallyloxysilane, vinyltris(beta-methoxyethoxy)silane, vinyltriacetoxysilane and dimethyltetraethoxydisiloxane.

Of these compounds, esters, ethers, ketones and acid anhydrides are preferable.

17 The solid catalyst component can be prepared by any known methods using the above-mentioned solid product the titanium compound and if desired the electron donor compound For example, it is preferable to produce the solid catalyst component by bringing the solid product into contact with the electron donor compound and then bringing the obtained product into contact with the titanium compound There are no restrictions as to the condition under which the solid product is brought into contact with the electron donor compound Usually, the amount of the electror donor compound is 0.01 to 10 moles, preferably 0.05 to moles, per 1 mol of the solid product in terms of magnesium atom. The contact reaction may be carried out at 0 to 200oC, preferably 30 to 150 0 C for 5 minutes to 10 hours, preferably minutes to 3 hours. The reaction may be carried out in an inert hydrocarbon solvent such as pentane, hexane, heptane and octane.

There are no restrictions as to the condition under which the solid product is brought into contact with the titanium compound or the contact product of the solid product and the electron donor compound is brought into contact with titanium compound Usually, the amount of the titanium compound is 1 to 50 moles, preferably 2 to 20 moles, per 1 mol of magnesium in the solid product. The contact reaction is usually carried out at 0 to 2000C, preferably 30 to 150 0 C for 5 minutes to 10 hours, preferably 30 minutes to hours.

For the contact reaction, the titanium compound may be used alone as such if it is a liquid (like titanium tetrachloride); otherwise, it may be used in the form of solution in an inert hydrocarbon solvent (such as hexane, heptane and kerosene). Prior to the above-mentioned contact reaction, the solid product may be treated with any one of halogenated hydrocarbons, halogen-containing silicon compounds, halogen gases, hydrogen chloride or hydrogen "odide.

18 r r a Kal_. In addition, after the contact reaction, the reaction product should preferably be washed with an inert hydrocarbon (such as n-hexane and n-heptane).

The above-mentioned organometallic compounds which can be preferably used include an organic compound containing a metal belonging to Groups I to III of the Periodic Table. These metals include, for example, lithium, sodium, potassium, zinc, cadmium and aluminum, of which aluminum is preferable. Examples of the organometallic compound include alkyl lithium such as methyl lithium, ethyl lithium, propyl lithium and butyl lithium, and dialkyl zinc such as dimethyl zinc, diethyl zinc, dipropyl zinc and dibutyl zinc.

The organoaluminum compounds which can be used in the present invention are represented by the following formula: AlR 2 mX 2 3-m wherein R 2 is an alkyl group having 1 to 10 carbon atoms, cycloalkyl group or aryl group; m is an integer of 1 to 3; and X 2 is a halogen atom such as chlorine or bromine.

Examples of the organoaluminum compound include trialkylaluminum compounds such as trimethylaluminum, triethylaluminum, triisopropylaluminum, triisobutylaluminum and trioctylaluminum; and dialkylaluminum monohalide compounds such as diethylaluminum monochloride, dipropylaluminum monochloride and dioctylaluminum monochloride.

The above-mentioned electron donor compouds can be used together if desired.

In this case, the above-mentioned electron donor compounds which can be used to prepare the above solid catalyst component can be used as the electron donor compounds The electron donor compound to be used may be the same as or different from the electron donor compounds to be used to prepare the above solid catalyst component 19

T

The polymerization conditions for the polypropylene based resins according to the present invention are not particularly limited. For example, using the above-mentioned high stereoregular catalyst, after a crystalline homopolymer or copolymer of propylene is produced in the former stage of polymerization in a homopolymerization vessel, propylene and the other alpha-olefin are subjected to random copolymerization in the presence of the above homopolymer or copolymer in the latter stage of polymerization (Japanese Patent Application No.

106318/1991).

In this case, in the former stage of polymerization, a crystalline homopolymer or copolymer of propylene is produced.

However, in this stage, the polymerization can be divided into two or more steps. Further, prior to substantial polymerization, for the purposes of improving catalystic activity, bulk density, flowability or the like, pre-polymerization treatment to bring a catalyst into contact with a small amount of propylene may be performed. One example of the pre-polymerization treatment is described in, for example, Japanese Patent Application Publication No. 45244/1982.

The former stage polymerization can be conducted in the presence or absence of an inert solvent in the liquid phase or gas phase. The suitable amount of each catalyst component can be appropriately selected depending upon its kind or the like.

In the former stage polymerization, to obtain a block copolymer having high stiffness, a crystalline homopolymer or copolymer of propylene is produced. In the case of producing copolymers, comonomers include alpha-olefins other than propylene, such as those having 2 to 10 carbon atoms such as 1-butene, 1-pentene, 1-hexene, 4-methyl-l-pentene, 1-octene and 1-decene.

The polymerization temperature used in producing the homopolymer or copolymer can be appropriately selected. For example, the polymerization temperature may range about 50 to 20 100 0 C, preferably about 60 to 90 0 C. Further, the polymerization pressure can be appropriately selected. For example, the polymerization pressure may range about 1 to 200 Kg/cm 2

G,

preferably about 1 to 100 Kg/cm 2

G.

In the case of using liquid phase polymerization, propylene or an inert solvent can be used as a liquid solvent.

Such inert solvents include, for example, propane, butane, pentane, hexane, heptane, decane and kerosene.

In the latter stage polymerization, in the presence of the crystalline propylene homopolymer or copolymer containing a catalyst obtained in the former stage, random copolymerization of propylene and the other alpha-olefin is carried out. The random copolymerization is usually carried out following to the former stage polymerization to produce crystalline propylene homopolymer or copolymer.

The random copolymerization can be carried out in the liquid phase or the gas phase. If the gas phase polymerization is adapted, the whole amount of the copolymer can be introduced into the block copolymer, resulting in high yield with respect to olefins consumed. This is particularly effective for industrial use.

The other alpha-olefins which can be used in the random copolymerization include, for example, ethylene, 1-butene, 1-pentene, 1-hexene, 4-methyl-l-pentene, 1-octene and 1-decene.

Preferred is ethylene or a combination of ethylene and a C4-C alpha-olefin.

The polypropylene based resin compositions according to the present invention may comprise at least the above-mentioned polypropylene based resin of the present invention, and may comprise if desired EPR, EPDM, polyethylene, EBR, polybutne-1 or the like.

Further, the polypropylene based resin compositions according to the present invention may comprise, if desired, 21 additives such as several stabilizers, pigments, dispersing agents and nucleating agents.

pr rie-r re-A Further, the secondiembodiment of the present invention provides a polypropylene based resin characterized by comprising: a propylene polymer having a content of alpha-olefin other than propylene of not more than 4 mole percent, and the following properties and a pentad fractioni (mmmm fraction) measured by 13 C-NMR of not less than 96.0 percent, a main elution fraction peak position of not less than 117.0 0 C and a peak half value width of less than 4.0, these values being measured by the temperature raising separation method, and an intrinsic viscosity of not less than 2.0 dl/g, but not more than 5.0 dl/g; and, a rubber content measured by pulse NMR of at least 8 percent.

The second embodiment of the present invention will be described in more detail.

First, each property will be described in detail.

The content of alpha-olefin other than propylene can be same as that described before for the first embodiment of the present invention.

The pentad fraction (mmmm fraction) can be same as that described before for the first embodiment of the present invention.

The Main Elution Peak Position and Peak Half Value Width: The temperature raising separation method was already described before for the first embodiment of the present invention.

The4polypropylene based resins according to the present invention have a main elution peak position of at least 117.0oC, preferably at least 117.5 0 C, more preferably at least 118.0C.

Further, the peak half value width is less than 4.0, preferably 22 less than 3.8, more preferably less than 3.4. If the main elution peak position is less than 117.0 0 C, the resultant polymer will have decreased crystallization degree, leading to decrease in stiffness and heat strength. Further, if the peak half value width is 4.0 or more, the stiffness and heat resistance of the resultant polymer will be also decreased to the same level of a conventional polypropylene.

Intrinsic Viscosity As used herein, the intrinsic viscosity is a value measured in decalin at 135 0

C.

_(zop'evr c Po\ P<r& cberr\scr tL(M The4polypropylene based resins according to the present invention have an intrinsic viscosity of 2.0 to 5.0 dl/g, preferably 2.0 to 4.0 dl/g, more preferably 2.0 to 3.5 dl/g. If the intrinsic viscosity is less than 2.0 dl/g, the impact strength of the resultant polymer will be insufficient. If the intrinsic viscosity exceeds 5.0 dl/g, the moldability of the resultant polymer will be poor.

Rubber Component Content: As used herein, the rubber component content means a value obtained from the Pulse NMR analysis made under the following conditions.

Analysis: In accordance with the techniques by Nishi et al (K.

Fujimoto, T. Nishi and R. Kado, Polym. 3.448(1972)), FID (Free Induced Decrease) is separated into three components showing different 1H spin-glide relaxation time (T2H). Then, among these three components, a component having the longest T2H is regarded as a rubber component, and the content of such fraction is defined as rubber component content.

The polypropylene based resin according to the present invention have a rubber component content measured by the Pulse NMR of not less than 8 percent, preferably 10 to 30 percent, more preferably 10 to 25 percent. If the rubber component content is 23 less than 8 percent, the Izod impact strength of the resultant polymer will be decreased.

A process for producing the polypropylene based resin having the above properties according to the present invention can be the same as that described before for the first embodiment of the present invention. In this case, a polymerization ratio of propylene to the other olefin may range, in molar ratio, 10/90 to 90/10, preferably 20/80 to 89/20.

Further, the thirdAembodiment of the present invention provides a polypropylene based resin characterized by comprising: a propylene polymer having a content of alpha-olefin other than propylene of not more than 4 mole percent, and the following properties and a pentad fraction (mmmm fraction) measured by 13 C-NMR of not less than 96.0 percent, a main elution fraction peak position of not less than 118.0 0 C and a peak half value width of less than 3.4, these values being measured by the temperature raising separation method, and an intrinsic viscosity of not less than 0.5 dl/g, but not more than 2.0 dl/g; and, a propylene copolymer having an intrinsic viscosity of not less than 3.0 dl/g.

Further, the polypropylene based resin compositions according to the third embodiment of the present invention comprise at least the above polypropylene based resin, and may comprise if desired the other resins such as EPR, EPDM and polyethylene.

The third embodiment of the present invention will be described in more detail.

First, each property will be described in detail.

The content of alpha-olefin other than propylene can be same as that described before for the first embodiment of the present invention.

24 JB r.

The pentad fraction (mmmm fraction) can be same as that described before for the first embodiment of the present invention.

The Main Elution Peak Position and Peak Half Value Width: The temperature raising separation method was already described before for the first embodiment of the present invention.

The propylene copolymers contained in the polypropylene based resins according to the present invention have a main elution peak position of at least 118.0 0 C, preferably at least 118.5 0 C, more preferably at least 119.0oC. Further, the peak half value width is less than 3.4, preferably less than 3.2, more preferably less than 3.0. If the main elution peek position is less than 118.0 0 C, the resultant polymer will not exhibit effects derived from the limitation of tb- intrinsic viscosity to a prescribed range, as well as wil- exhibit insufficient stiffness and heat strength. Further, if the peak half value width is 3.4 or more, the resultant polymer will not exhibit effects derived from the limitation of the intrinsic viscosity to a prescribed range, as well as will exhibit insufficient stiffness and heat strength.

Intrinsic Viscosity As used herein, the intrinsic viscosity is a value measure(. -n decalin at 135 0

C.

The propylene copolymers contained in the polypropylene based resins according to the present invention have an intrinsic viscosity of 0.5 to 2.0 dl/g, preferably 0.7 to 1.5 dl/g, more preferably 0.8 to 1.2 dl/g. If the intrinsic viscosity is less than 0.5 dl/g, the impact strength of the resultant polymer will be insufficient. If the intrinsic viscosity exceeds 2.0 dl/g, balance between stiffness and impact strength of the resultant polymer will be equivalent to that of a conventional polypropylene.

25 fiji~ t~ The polypropylene based resins according to the present invention may comprise the other propylene copolymer having the intrinsic viscosity described below in addition to the propylene copolymer having the above-mentioned properties and As used herein, the intrinsic viscosity is a value measured in decalin at 135 0

C.

The above-mentioned propylene copolymers have an intrinsic viscosity of at least 3.0 dl/g, preferably at least dl/g, more preferably at least 4.0 dl/g. If the intrinsic viscosity is less than 3.0 dl/g, the impact strength of the resultant polymer will be insufficient.

A process for producing the polypropylene based resins having the above-mentioned properties is the same as that described before for the first embodiment of the present invention.

Further, the fourth embodiment of the present invention provides a polypropylene resin characterized by comprising a propylene polymer having: a pentad fraction (mmmm fraction) measured by 13C-NMR of not less than 96.0 percent, a main elution fraction peak position of not less than 118.0C and a peak half value width of less than 3.4, these values being measured by the temperature raising separation method, and a molecular weight distribution index (PDi) of not more than the molecular weight distribution index being calculated in accordance with the following equation: PDi W2/10W1 wherein W1 is an angle frequency when storage elasticity measured by tne melt-viscosity method is 2 X 105 dyn/cm 2 and W2 is an angle frequency when the storage elasticity is 2 X 103 dyn/cm 2 IK Z.

26 Further, the polypropylene based resin compositions according to the fourth embodiment of the present invention comprise at least the above polypropylene based resin, and may comprise if desired the other resins such as EPR, EPDM and polyethylene.

The fourth embodiment of the present invention will be described in more detail.

First, each property will be described in detail.

The pentad fraction (mmmm fraction) can be the same as that described before for the first embodiment of the present invention.

The Main Elution Peak Position and Peak Half Value Width: The temperature raising separation method was already described before for the first embodiment of the present invention.

The propylene polymers contained in the polypropylene based resins according to the present invention have a main elution peak position of at least 118.0 0 C, preferably at least 118.50C, more preferably at least 119.0 0 C. Further, the peak half value width is less than 3.4, preferably less than 3.1, more preferably less than 3.0. If the main elution peak position is less than 118.0 0 C, the resultant polymer will have decreased crystallization degree, leading to decrease in stiffness and heat strength. Further, if the peak half value width is 3.4 or more, the stiffness and heat resistance of the resultant polymer will be also insufficient.

Molecular Weight Distribution Index (PDi) The molecular weight distribution index (PDi) is represented by the following equation: PDi W2/10W1 wherein Wl is an angle frequency when storage elasticity measured by the melt-viscosity method is 2 X 10 5 dyn/cm 2 and W2 27 is an angle frequency when the storage elasticity is 2 X 10 3 dyn/cm 2 The shearing speed dependability of the storage elasticity is dependent upon the molecular weight distribution. As the melt elasticity on the lower shearing speed side decreases, the relaxation of the molecules to which deformation is applied, occurs faster and the orientation decreases.

The polypropylene according to the present invention have a PDi of not more than 15, preferably not more than 12. If the PDi exceeds 15, the resultant injection-molded article may suffer big warp or deformation.

A process for producing the propylene resins having the above-mentioned properties according to the present invention is the same as that described before for the first embodiment of the present invention.

The polymerization conditions are not particularly limited. The polymerization may be carried out under the same conditions as used for the known process. For example, the polymerization may be performed at an olefin partial pressure higher than the atmospheric pressure, at a temperature of from -800C to +150 0 C, in the gas phase or liquid phase, and, if necessary, in the presence of an inrt hydrocarbon diluent.

Further, the fifth embodiment of the present invention pr'vides a polypropylene resin characterized by being composed of a propylene homopolymer having: a pentad fraction (mmmm fraction) measured by 13 C-NMR of not less than 96.0 percent, a main elution fraction peak position of not less than 118.0 0 C and a peak half value width of less than 3.4, these values being measured by the temperature raising separation method, and a melt index of not less than 0.01 g/10 min., but not more than 200 g/10 min.

28 Further, the polypropylene based resin compositions according to the fifth embodiment of the present invention comprise at least the above polypropylene based resin, and may comprise if desired the other resins such as EPR, EPDM and polyethylene.

The fifth embodiment of the present invention will be described in more detail.

First, each property will be described in detail.

The pentad fraction (mmmm fraction) can be the same as that described before for the first embodiment of the present invention.

The Main Elution Peak Position and Peak Half Value Width: The temperature raising separation method was already described before for the first embodiment of the present invention.

The propylene polymers contained in the polypropylene based resins according to the present invention have a main elution peak position of at least 118.0 0 C, preferably at least 118.5 0 C, more preferably at least 119.0 0 C. Further, the peak half value width is less than 3.4, preferably less than 3.1, more preferably less than 3.0. If the main elution peak position is less than 118.0 0 C, the resultant polymer will have decreased crystallization degree, leading to decrease in stiffness and heat strength. Further, if the peak half value width is 3.4 or more, the stiffness and heat resistance of the resultant polymer will be also insufficient.

Melt Index (MI): As used herein, the "melt index" means a value measured in accordance with JIS K7210.

The~polypropylene of the present invention have a MI of 0.01 to 200 g/10 min., preferably 0.1 to 200 g/10 min., more preferably 1.0 to 150 g/10 min. If the MI is less than 0.01 min., the resultant polymer may have low stiffness and heat 29 I K~ resistance. If the MI exceeds 200 g/10 min., undesirable low molecular weight components will be generated.

A process for producing the propylene resins having the above-mentioned properties according to the present invention is the same as that described before for the first embodiment of the present invention.

The polymerization conditions are not particularly limited. The polymerization may be carried out under the same conditions as used for the known process. For example, the polymerization may be performed at an olefin partial pressure higher than the atmospheric pressure, at a temperature of from 0 C to +150 0 C, in the gas phase or liquid phase, and, if necessary, in the presence of an inert hydrocarbon diluent.

The polymerization carried out under such conditions gives rise to a polyolefin powder having an almost complete sphericity and a sharp particle size distribution. In other words, the polyolefin powder has a sphericity of smaller than 1.60 and a particle size distribution index of smaller than 5.0, as mentioned above.

Further, the sixthAembodiment of the present invention provides a polypropylene resin characterized by being composed of a propylene homopolymer having: a pentad fraction (mmmm fraction) measured by 13 C-NMR of not less than 96.0 percent, a main elution fraction peak position of not less than 117.OOC and a peak half value width of less than 4.0, these values being measured by the temperature raising separation method, a melt index of not less than 0.01 g/10 min., but not more than 3.0 g/10 min.

melt tension satisfying the following equation: T 5.2 logMI 3 7 71 wherein T is melt-tension measured at 2300C; and MI is melt index.

Further, the polypropylene based resin compositions according to the sixth embodiment of the present invention comprise at least the above polypropylene based resin, and may comprise if desired the other resins such as EPR, EPDM and polyethylene.

The sixth embodiment of the present invention will be described in more detail.

First, each property will be described in detail.

The pentad fraction (mmmm fraction) can be the same as that described before for the first embodiment of the present invention.

The Main Elution Peak Position and Peak Half Value Width: The temperature raising separation method was already described before for the first embodiment of the present invention.

The propylene polymers contained in the polypropylene based resins according to the present invention have a main elution peak position of at least 117.0oC, preferably at least 117.5 0 C, more preferably at least 118.0oC. Further, the peak half value width is less than 4.0, preferably less than 3.8, more preferably less than 3.4. If the main elution peak position is less than 117.0 0 C, the resultant polymer will have decreased crystallization degree, leading to decrease in stiffness and heat strength. Further, if the peak half value width is 4.0 or more, the stiffness and heat resistance of the resultant polymer will be also insufficient.

Melt Index (MI): As used herein, the melt index means a value measured in accordance with JIS K7210.

~rOY~I~e c~~ymrL ontL r\c The~polypropylene of the present invention have a MI of 0.01 to 3.0 g/10 min., preferably 0.1 to 3.0 g/10 min. If the MI is less than 0.01 g/0min., the resultant polymer may have low 31t'' stiffness and heat resistance. If the MI exceeds 3.0 g/10 min., it is not preferable since the melt tension of the resultant polymer will be decreased.

Melt Tension: In the polypropylene resins according to the present invention, the relation between the melt tension measured at 230 0 C and the melt index should satisfy the following equation: T -5.2 logMI wherein T is melt-tension measured at 2300C; and MI is melt index.

If the melt tension is less than the value of (-5.2 logMI it is not preferable since the products will suffer big draw down during the molding of sheets or blown products.

A process for producing the propylene resins having the above-mentioned properties according to the present invention is the same as that described before for the first embodiment of the present invention.

The polymerization conditions are not particularly limited. The polymerization may be carried out under the same conditions as used for the known process. For example, the polymerization may be performed at an olefin partial pressure higher than the atmospheric pressure, at a temperature of from 0 C to +1500C, in the gas phase or liquid phase, and, if necessary, in the presence of an inert hydrocarbon diluent.

In this case, it is preferable that the polypropylene of the present invention be substantially produced in one stage polymerization. According to this process, less expensive products having good quality can be produced.

The polyolefin powders obtained as above have an almost complete sphericity and a sharp particle size distribution. In other words, the polyolefin powder has a sphericity of 32

V

!l rr, smaller than 1.60 and a particle size distribution index of smaller than 5.0, as mentioned above.

As described before, the polypropylene resins and their compositions according to the present invention, exhibit extremely high stiffness, heat resistance and impact strength with these properties being well balanced.

Further, the polypropylene resins and their compositions according to the present invention exhibit excellent stiffness and heat resistance, as well as good dimensional stability and ability to avoid warping and deformation of the products.

Furthermore, the polypropylene resins and their compositions according to the present invention have extremely high stiffness, heat resistance and melt tension, and also are cost effective.

Brief Description of the Drawings Fig. 1 is an analysis chart showing the main elution peak position and the peak half value width measured by the temperature raising separation method; and Fig. 2 is a graph showing relationship between the rubber component content and the Izod impact strength.

Best Embodiment For Carrying Out the Invention The present invention will be described in more detail with reference to the following Examples and Comparative Examples; however the present invention is not limited to the following Examples.

In the following Examples and Comparative Examples, the following reagents were used.

Metallic Magnesium: Granular Form (350 micrometers in average particle size.) Ethanol: Reagent First Grade (Made by Wako Junyaku Co.) Iodine: Reagent First Grade (Made by Wako Junyaku Co.) Examples 1 to 3 and Comparative Example 1 -1 33

IN)

rUr

CJ~

Preparation of Solid Product: A glass reactor (inner volume: about 6 liters) equipped with a stirrer, which was sufficiently purged with nitrogen gas, was charged with 2430 g of ethanol, 16 g of iodine and 160 g of metallic magnesium. The reaction was carried out by heating with stirring under refluxing conditions until no hydrogen was evolved any longer to obtain a solid product. The reaction solution containing the solid product was dried under reduced pressure to obtain a solid product The solid product obtained had a sphericity of 1.20 and a particle size distribution index (P) of 1.8.

Preparation of Solid Catalyst Component: A three-mouth glass flask (inner volume: 50 mililiters) sufficiently purged with nitrogen gas, was charged with 16 g of the above-mentioned solid product (not ground), 80 ml of purified heptane, 2.4 ml of silicon tetrachloride and 2.3 ml of diethyl phthalate. After, 77 ml of titanium tetrachloride were added with agitation while the reaction system was kept at 90 0

C,

the reaction was carried out at 110 0 C for 2 hours. Then, the solid components were removed from the reaction mixture, and washed with purified heptane heated to 80 0 C. After 122 ml of titanium tetrachloride were further added, the reaction was further carried out at 110 0 C for 2 hours. Then, the reaction product was sufficiently washed with purified heptane to obtain a solid catalyst component Propylene Polymerization: A styrene steel-made autoclave (inner volume: about liters) was charged with 30 g of polypropylene powders, sufficiently purged with nitrogen gas, and then charged with mmol of triethylaluminum, 0.5 mmol of diphenyldimethoxysilane and 0.01 mmol of the above-mentioned solid catalyst component in terms of titanium atom. Thereafter, 0.7 Kg/cm 2 G of hydrogen and 27.3 Kg/cm 2 G of propylene were introduced into the reaction 34 system. Then, the polymerization was carried out under a total pressure of 28.0 Kg/cm 2 at 70 0 C for 1 hour.

Subsequently, the reaction gas in the reaction system was purged. Then, while ethylene and propylene were introduced at the same volume ratio to adjust the amount of hydrogen so that the intrinsic viscosity as shown in Table 1 was obtained, the polymerization was carried out under a total pressure of 10.0 Kg/cm 2 at 55 0 C. The polymerization time was adjusted so that the resultant polymer had the copolymerized portion ratios as shown in Table 1, to obtain polypropylene based resins.

Comparative Example 2 The polymerization was carried out in the same manner as in Example 1 to obtain polypropylene based resin, except that the propylene/ethylene volume ratio of the feeding gas for the propylene copolymerization, was changed from 5/5 to 4/6.

Comparative Example 3 Preparation of Solid Catalyst Component: A glass reactor equipped with a stirrer, which was sufficiently purged with nitrogen gas, was charged with 30 g of anhydrous magnesium chloride, 150 ml of purified n-heptane and ethanol whose amount is 6 more moles of the magnesium chloride.

The reaction mixture was heated and stirred under refluxing conditions for 2 hours. Thereafter, the reaction mixture was supplied by pressure to a glass reactor equipped with a stirrer, which was charged with 1500 ml of titanium chloride cooled to 0 C, was gradually heated to room temperature with agitation.

Then, 160 ml of di-n-butyl phthalate were added. The reaction mixture was heated and stirred at 110 0 C for 2 hours.

The solid components obtained were removed from the reaction mixture, and further heated to 110 0 C and stirred for 2 hours in 150 ml of titanium tetrachloride. Then, the reaction 35 product was sufficiently washed with purified n-heptane to obtain a solid catalyst component.

Propylene Polymerization: The polymerization was carried out in the same manner as in Example 3 to obtain a polypropylene based resin, except that the solid catalyst component obtained as above was used.

Using the polypropylene based resins obtained in the above Examples 1 to 3 and Comparative Examples 1 to 3, the pentad fraction (mmmm%), the main elution peak position (Tmax) (OC) and the peak half value width measure by the temperature raising separation method, the intrinsic viscosity (dl/g) and the rubber component content were measured in accordance with the following measurement methods and measurement conditions, respectively. The results are as shown in Table 1.

Pentad Fraction The pentad fraction was measured using JNM-EX400 (Manufactured by Nihon Electric: 13 C nuclear resonance frequency 100 MHz) under the following conditions.

Measurement Mode: Scholar Decoupling Method Pulse Width: 9.0 gs (450) Pulse Repeating Time: 4 seconds Integrated Number: 10000 Times Solvent: 1,2,4-Trichlorobenzene/heavy benzene solvent (90/10 Vol. Sample Concentration: 200 mg/3.0 ml Solvent Measuring Temperature: 130 0

C

In this case, the pentad fraction was evaluated by measuring split peaks in the methyl group region from the 13

C-NMR

spectrum. In addition, the peaks in the methyl group region were identified according to the description of "Macromolecules, 13(2), 267(1980)(A. Zambelli et al)".

36 Main Elution Peak Position and Half Value Width: These were measured under the following conditions.

Solvent: Orthodichlorobenzene Flow Rate: 2 ml/min.

Heat Up Rate: 20 0 C/hr Detector: Infrared Detector for Liquid Chlomatography Measuring Frequency: 3.41 pm Column: 1.07 cm X 30 cm Filler: CHLOMOSOLVE P Concentration: 7.5 mg/20 ml Filling Amount: 2 ml Column Temp. Distribution: Within +0.2 0

C

In this case, a sample solution was introduced at 135 0

C

into a column, gradually cooled at a rate of 2 0 C/hr so as to make a polymer adsorbed to a filler and then the column was cooled to room temperature. Thereafter, while the column temperature was elevated under the above conditions, the polymer concentration at each temperature was detected by the infrared detector.

Intrinsic Viscosity [r] The intrinsic viscosity was measured in decalin at 135 0

C.

Rubber Component Content By Pulse NMR The rubber component content was measured with a NMR equipment (CPX-90: Manufactured by Bulcar Co.) under the following conditions.

Measuring Temperature: Room Temperature (about 23 0

C)

Pulse Lines used in Measurement: The solid echo method (Refer to, "Macromolecule Measuring Method Structure and Physical Properties" Latter Vol., by Macromolecule r/ 2 37 7I I rt! <yi "tr.S^c Association, 1973; and "Lecture for Macromolecule Experiments", Vol. 12, Nuclear Resonance of Macromolecule, by Kyoritsu, 1975).

900 Pulse Width: 2 is Restoring Time (time required to restore magnetization in the direction of static magnetic field to equilibrium value): second NMR Sample Tube: Outer Diameter: 10 Inner Diameter: 8 Made of Pyrex glass Preparation of Samples: A sample prepared by being subjected to press-molding at 220 0 C (cooling temp.: 30 0

C)

was cut into specimens of 1 mm square.

Further, the resin obtained was incorporated with 0.1 of phenol type antioxidant and 0.1 of calcium stearate, pelletized with a 20 mm single axle granule maker, subjected to press board molding (molding temp.: 2200C, cooling temp.: 30 0

C),

to obtain samples for measurement of physical properties. Then, the physical properties of the samples were measured.

The physical properties measured included tensile elasticity (Kg/cm 2 thermal deformation temperature (load flexure temperature) (HDT) (OC) and Izod impact strength (-20 0

C).

The results are as shown in Table 1. In addition, each of physical properties was evaluated in accordance with the following methods.

Tensile Elasticity The tensile elasticity was measured in accordance with JIS-K7113.

Heat Deformation Temperature The heat deformation temperature was measured in accordance with JIS-K7207. In addition, the samples for -38- -x measurement were not subjected to annealing. The bending stress applied to the samples was set to 4.6 Kg/cm 2 Izod Impact Strength The Izod impact strength was measured in accordance with JIS-K7110.

39 Ka ii i' I-~1 Ii/) .59.

'0 Table 1 Example Comparative Example 1 2 3 1 2 3 Propylene Polymer mmmm Fraction 97.0 96.9 d7.1 96.9 97.0 97.5 o 3.0 2.9 3.8 3.1 3.2 4.2 Tmax 118.8 119.0 118.6 118.9 118.8 117.0 [7 (dl/g) 1.0 0.9 4.0 1.1 2.5 Propylene Copolymer kind of Comonomer Ethylene Ethylene Ethylene Ethylene Ethylene Ethylene uopolymerized Portion Ratio 35 44 56 22 30 Feed Gas Formulation 5/5 5/5 5/5 5/5 4/6 (Propylene Olefin Vol Ratio) [7 (dl/g) 3.0 3.2 3.5 4.1 3.2 Resultant Polymer Rubber Component Content 33 40 53 20 25 53 (dl/g) 1.7 1.9 3.7 1.8 2.7 Tensile Elasticity (Kg/cm 2 10100 9600 9300 14000 12200 6700 HDT 87 85 85 111 96 66 Impact Strength (Kgcm/cm) 72.8 84.1 98.8 6.3 10.3 78.5 (NB) (NB) (NB) (NB) Example 4 Preparation of Solid Product: A solid reaction product was obtained in the same manner as in Example i. The reaction solution containing the solid product was dried under reduced pressure to obtain a solid product The solid product obtained had a sphericity (S) of 1.20 and a particle size distribution index of 1.8.

Preparation of Solid Catalyst Component: A solid catalyst component was obtained in the same manner as in Example 1.

Propylene Polymerization: A styrene steel-made autoclave (inner volume: about liters) was charged with 30 g of polypropylene powders, sufficiently purged with nitrogen gas, and then charged with mmol of triethylaluminum, 0.5 mmol of diphenyldimethoxysilane and 0.01 mmol of the above-mentioned solid catalyst component in terms of titanium atom. Thereafter, propylene was introduced into the reaction system so as to adjust the amount of hydrogen as shown in Table 2. Then, the polymerization was carried out under a total pressure of 28.0 Kg/cm 2 at 70 0 C for 1 hour.

Subsequently, the reaction gas in the reaction system was purged.

Then, while ethylene and propylene were introduced at the same volume ratio to adjust the amount of hydrogen so that the intrinsic viscosity as shown in Table 2 was obtained, the polymerization was carried out under a total pressure of Xg/cm 2 at 55 0 C for 20 minutes, to obtain a polypropylene based resin.

Example The propylene polymerization was carried out in the same manner as in Example 4 to obtain a polypropylene resin, except that the polymerization time for the ethylene/propylene copolymerization was changed to 40 minutes.

41 Example 6 The propylene polymerization was carried out in the same manner as in Example 4 to obtain a polypropylene resin, except that the amount of hydrogen used in the propylene homopolymerization stage was increased, and the pressure in the ethylene/propylene copolymerization stage was changed to 10.0 Kg/cm 2 Comparative Example 4 The propylene polymerization was carried out in the same manner as in Example 4 to obtain a polypropylene resin, except that the feed gas formulation in the ethylene/propylene copolymerization stage (propylene/ethylene volume ratio) was changed from 5/5 to 4/6, and the polymerization time was changed to 15 minutes.

Comparative Example A stainless autoclave (inner volume: 10 liters) was charged with 5 1 of purified heptane, 5 ml of diethylaluminum chloride (DEAC) and 0.7 g of TiC1 3 catalyst (Type 01: Manufactured by Solbey Co.).

A prescribed amount of hydrogen and propylene were introduced into the reaction system and the polymerization was carried out at 70 0 C under a total pressure of 8.0 Kg/cm 2 for minutes. Then, the reaction system was purged from the reaction system, and again mixed gas of ethylene and propylene (propylene/ethylene volume ratio of 4/6) was supplied. Then, the polymerization was carried out at 55 0 C for 20 minutes while the total pressure was kept at 5 to 7 Kg/cm 2 Thereafter, the reaction gas was purged from the reaction system, and 50 ml of butyl alcohol were added. After the reaction mixture was heated and stirred at 70 0 C for 30 minutes, a polymer in the slurry was filtered off, and dried under reduced pressure, to obtain a propylene copolymer.

N 42 Comparative Example 6 The polymerization was carried out in the same manner as in Comparative Example 5 to obtain a polypropylene resin, except that the feed gas formulation in the ethylene/propylene copolymerization stage (propylene/ethylene volume ratio) was changed to 5/5, and the polymerization time was changed to minutes.

Using the polypropylene based resins obtained in the above Examples 4 to 6 and Comparative Examples 4 to 6, the pentad fraction (mmmm%), the main elution peak position (Tmax) (OC) and the peak half value width measured by the temperature raising separation method, intrinsic viscosity (dl/g) and the rubber component content were measured in accordance with the above-mentioned measurment methods and measurment conditions, respectively. The results are as shown in Table 2.

Further, samples for measurement of physical properties were prepared in the same manner as in Example 1, and the physical properties thereof were measured. The results are as shown in Table 2. In addition, each of the physical properties was evaluated in the same manner as in Example 1.

'-43 Table 2 Comp. Comp. Comp.

Example Example Example Example Example Example -4 -5 -6 -4 -5 -6 (Former Stage Polymerization) mmmm Fraction 96.9 97.1 96.9 96.9 95.8 95.6 a- 3.8 3.6 3.3 3.8 4.3 4.4 Tmax 118.2 118.7 118.8 118.3 114.0 113.7 H (dl/g) 3.3 3.1 2.3 3.4 3.0 3.1 (Latter Stage Polymerization) Kind of Comonomer Ethylene -t -i Copolymerized Portion Ratio(%) 10 15 25 11 10 17 Feed Gas Formulation 5/5 5/5 5/5 4/6 4/6 C02 Olefin (Vol Ratio) (Resultant Polymer) Rubber Component Content 9 13 21 6 7 [7 T (dl/g) 3.2 3.1 2.5 3.4 3.1 Tensile Elasticity (Kg/cm 2 14,100 13,000 12,300 16,500 14,900 12,000 HDT 110 104 100 122 106 89 Izod Impact Strength (Kgcm/cm) 3.7 5.1 7.5 2.1 2.1 4.8 Examples 7 to 9 and Comparative Examples 7 to 8 Preparation of Solid Product: A solid product was obtained in the same manner as in Example 1. The solid product obtained had a sphericity of 1.20 and a particle size distribution index of 1.8.

Preparation of Solid Catalyst Component: A solid catalyst component was obtained in the same manner as in Example i.

Propylene Polymerization: A styrene steel-made autoclave (inner volume: about liters) was charged with 30 g of polypropylene powders, sufficiently purged with nitrogen gas, and then charged with mmol of triethylaluminum, 0.5 mmol of diphenyldimethoxysilane and 0.01 mmol of the above-mentioned solid catalyst component in terms of titanium atom. After 0.7 Kg/cm 2 G of hydrogen and 27.3 Kg/cm 2 G of propylene were introduced into the reaction system, the polymerization was carried out under a total pressure of 28.0 Kg/cm 2 at 70 0 C for 1 hour.

Subsequently, the reaction gas in the reaction system was purged. Then, while ethylene and propylene were introduced at the same volume ratio to adjust the amount of hydrogen so that the intrinsic viscosity as shown in Table 3 was obtained, the polymerization was carried out under a total pressure of 10.0 Kg/cm 2 at 55 0 C. The polymerization time was adjusted so that the resultant polymer had the copolymerized portion ratios as shown in Table 3, to obtain polypropylene based resins.

Comparative Example 9 Preparation of Solid Catalyst Component: A solid catalyst component was obtained in the same manner as in Example 1.

Propylene Polymerization: 45 The polymerization was carried out in the same manner as in Example 7 to obtain a polypropylene based resin, except that the solid catalyst component obtained was used.

Using the polypropylene based resins obtained in the above Examples 7 to 9 and Comparative Examples 7 to 9, the pentad fraction (mmmm%), the main elution peak position (Tmax) (OC) and the peak half value width measured by the temperature raising separation method and the intrinsic viscosity (dl/g) were measured in accordance with the above-mentioned measurement methods and measurement conditions, respectively. The results are as shown in Table 3.

Further, samples for measurement of physical properties were prepared in the same manner as in Example i, and the physical properties thereof were measured. The results are as shown in Table 3. In addition, each of the physical properties was evaluated in the same manner as in Example i.

46 r i1.' t I Table 3 Example Comparative Example 7 8 9 7 8 9 Propylene Polymer (A) mmmm Fraction 97.0 96.9 96.9 97.1 97.0 97.5 3.0 2.9 3.1 3.1 3.2 3.6 Tmax 118.8 119.0 118.9 119.1 118.8 117.0 [7 (dl/g) 1.0 0.9 1.1 1.2 2.5 Propylene Copolymer B kind of Comonomer Ethylene Ethylene Ethylene Ethylene Ethylene Ethylene Copolymerized Portion Ratio 15 14 22 16 14 Feed Gas Formulation 5/5 5/5 5/5 5/5 5/5 (Propylene Olefin Vol Ratio) [7 (dl/g) 3.0 3.2 4.1 2.0 3.2 Resultant Polymer [7 (dl/g) 1.3 1.2 1.8 1.3 2.6 1.3 Tensile Elasticity 16700 17600 14000 16200 14700 15100 HDT 123 122 111 118 110 109 Impact Strength (Kgcm/cm) 3.5 3.1 6.3 2.2 3.4 Examples 10 to 11 Preparation of Solid Product A solid product was obtained in the same manner as in Example 1. The solid product obtained had a sphericity of 1.20 and a particle size distribution index of 1.8.

Preparation of Solid Catalyst Component: A solid catalyst component was obtained in the same manner as in Example 1.

Propylene Polymerization: A styrene steel-made autoclave (inner volume: about liters) was charged with 30 g of polypropylene powders, sufficiently purged with nitrogen gas, and then charged with mmol of triethylaluminum, 0.5 mmol of diphenyldimethoxysilane and 0.01 mmol of the above-mentioned solid catalyst component in terms of titanium atom. While the amount of hydrogen was adjusted so that the melt index of the resultant polymer as shown in Table 4 was obtained, the polymerization was carried out under a total pressure of 28.0 Kg/cm 2 at 70 0 C for 2 hours, to obtain a propylene homopolymer.

Examples 12 to 13 Preparation of Solid Product A solid product was obtained in the same manner as in Example Preparation of Solid Catalyst Component A solid catalyst component was obtained in the same manner as in Example Propylene Polymerization: A styrene steel-made autoclave (inner volume: about liters) was charged with 30 g of polypropylene powders, sufficiently purged with nitrogen gas, and then charged with mmol of triethylaluminum, 1.0 mmol of diphenyldimethoxysilane and 0.02 mmol of the above-mentioned solid catalyst component in terms of titanium atom. While the amount of hydrogen was S- 48- R j S~ v adjusted so that the intrinsic viscosity as shown in Table 4 was obtained, the polymerization was carried out under a total pressure of 28.0 Kg/cm 2 at 70 0 C for 1 hour.

Subsequently, the reaction gas in the reaction system was purged. Then, while ethylene/propylene mixed gas (same volume ratio) was introduced to adjust the amount of hydrogen so that the melt index of the resultant polymer as shown in Table 4 was obtained, the polymerization was carried out under a total pressure of 3.0 Kg/cm 2 at 55 0 C for 20 minutes, to obtain a copolymerized polymer.

Comparative Examples 10 to 11 A stainless autoclave (inner volume: 10 liters) was charged with 5 1 of purified heptane, 5 ml of diethylaluminum chloride (DEAC) and 0.7 g of TiC13 catalyst (Type 01: Manufactured by Solbey Then, while the amount of hydrogen was adjusted so that the melt index as shown in Table 4 was obtained, the polymerization was carried out at 700C under a total pressure of 8.0 Kg/cm 2 G for 90 minutes. Thereafter, the reaction gas was purged from the reaction system, and 50 ml of butyl alcohol were added. After the reaction mixture was heated and stirred at 70 0 C for 30 minutes, a polymer in the slurry was filtered off, and dried under reduced pressure, to obtain a propylene polymer.

Comparative Examples 12 to 13 The propylene homopolymerization was carried out in the same manner as in Comparative Examples 10 to 11. Then, the reaction gas was purged from the reaction system. While mixed gas of ethylene and propy.ene (the same volume ratio) was again supplied to the reaction system to keep a total pressure of 5 to 7 Kg/cm 2 the polymerization was carried out at 550C for minutes. Then, the reaction gas was purged from the reaction system, 50 ml of butyl alcohol were added. After the reaction 49 mixture was heated and stirred at 70 0 C for 30 minutes, a polymer in the slurry was filtered off, and dried under reduced pressure, to obtain a propylene polymer.

Comparative Example 14 A polymer prepared in the same manner as in Comparative Example 12 was incorporated with 300 ppm of an organic peroxide (PERKADOX 14: Manufactured by Kayaku Nury 0.1 of phenol type antioxidant and 0.1 of calcium stearate, pelletized with a mm single axle granule maker, subjected to press board molding.

Using the polypropylene based resins obtained in the above Examples 10 to 13 and Comparative Examples 10 to 14, the pentad fraction (mmmm%), the main elution peak position (Tmax) (OC) and the peak half value width measured by the temperature raising separation method and the intrinsic viscosity (dl/g) were measured in accordance with the above-mentioned measurement methods and measurement conditions, respectively. The molecular weight distribution index (PDi) and the melt index (MI) were measured in accordance with the following measurement methods and measurement conditions. The results are as shown in Table 4.

Molecular Weight Distribution Index (PDi) The molecular weight distribution index was measured under the following conditions.

Measurment Equipment: SYSTEM-4 manufactured by Leometrix Co.

Shape of Measured Portion: Corn or Plate Shape Measurment Conditions: 170 0 C, Sinusoidal Strain Melt Index (MI) 50 The melt index was measured in accordance with JIS K-7210.

Further, samples for measurement were prepared in the same manner as in Example 1, and the physical properties thereof were measured. In addition, the resin obtained in Comparative Example 14 was provided as it was for the measurement.

The results are as shown in Table 4. In addition, each of the physical properties was evaluated in accordance with the following methods.

Bending Elasticity The tensile elasticity was measured in accordance with JIS-K7203.

Heat Deformation Temperature (HDT) The heat deformation temperature was measured in the same manner as in Example 1.

Izod Impact Strength The Izod impact strength was measured in the same manner as in Example 1.

Molding Shrinkage The molding shrinkage was evaluated by measuring shrinkage in the MD and TD direction after a sample was molded with a metal mold (100 mm X 100 mm X 2 mm: mold temperature 45 0 C) at 220 0

C.

51 STable 4 Comp. Comp. Comp. Comp. Comp.

Example Example Example Example Example Example Example Example Example 11 12 13 10 11 12 13 14 (Former Stage Polymerization) nnmm Fraction 96.9 96.9 97.0 97.1 95.6 96.0 96.1 95.9 96.1 o- 3.1 3.2 3.0 3.0 4.4 4.8 4.4 4.2 4.4 Tmax 118.7 119.1 118.8 118.9 113.7 114.1 113.9 114.2 113.9 H (dl/g) 1.6 1.3 1.0 1.0 1.7 1.3 1.0 0.9 (Copolymerized Portion) Kind of Comonomer Ethylene Ethylene Ethylene Ethylene Ethylene Copolymerized Portion Ratio(%) 15 16 16 14 16 EP (dl/g) 3.2 3.1 3.4 3.2 3.4 (Resultant Polymer) M i (g/lOmin) 9.5 23 21 30 9.2 24 22 33 (34)m PDi 12.4 11.2 8.3 8.7 25.2 32.6 29.1 31.9 14.0 Bending Elasticity(Kg/cm 2 21,500 22,000 15,900 16,300 16,000 17,400 12,000 12,400 10,900 HDT 135 139 124 123 110 112 100 105 98 Izod Impact Strength 3.7 3.7 3.5 3.4 2.9 (Kgcm/cm) Molding Shrinkage MD 1.58 1.48 1.46 1.47 1.86 1.70 1.65 1.77 1.56 TD 1.52 1.51 1.50 1.51 1.44 1.45 1.45 1.48 1.48 MD/TD Ratio 1.04 0.98 0.97 0.97 1.29 1.17 1.14 1.20 1.05 M i After Decomposition Example 14 Preparation of Solid Product A solid product was obtained in the same manner as in Example 1. The solid product obtained had a sphericity of 1.20 and a particle size distribution index of 1.8.

Preparation of Solid Catalyst Component A solid catalyst component was obtained in the same manner as in Example 1.

Propylene Polymerization: A styrene steel-made autoclave (inner volume: about liters) was charged with 30 g of polypropylene powders, sufficiently purged with nitrogen gas, and then charged with mmol of triethylaluminum, 0.5 mmol of diphenyldimethoxysilane and 0.01 mmol of the above-mentioned solid catalyst component in terms of titanium atom. After 0.7 Kg/cm 2 G of hydrogen and 27.3 Kg/cm 2 G of propylene were introduced into the reaction system, the polymerization was carried out under a total pressure of 28.0 Kg/cm 2 at 70 0 C for 2 hour, to obtain a propylene homopolymer.

:mple The polymerization was carried out in the same manner as in Example 14 to obtain a propylene homopolymer, except that 0.3 mmol of cyclohexylmethyldimethoxysilane were used instead of diphenyldimethoxysilane in the polymerization.

Example 16 The polymerization was carried out in the same manner as in Example 14 to obtain a propylene homopolymer, except that the amount of hydrogen introduced was increased to 2.0 Kg/cm 2 and the polymerization temperature was changed to 80 0 C in the propylene polymerization Comparative Example Preparation of Solid Catalyst Component: 53 54 0 A glass reactor equipped with a stirrer, which was sufficiently purged with nitrogen gas, was charged with 600 ml of n-heptane, 0.5 mol of diethylaluminum chloride and 1.2 mol of disoamyl ether. Then, the reaction was carried out at room temperature for 5 minutes.

A reactor separately provided, was charged with 4.0 mol of titanium tetrachloride. After the above reaction solution was added dropwise over a period of 180 minutes, the reaction was carried out at room temperature for 80 minutes. Further, the reaction mixture was heated to 75 0 C and stirred under heat conditioL.s for 1 hour.

After the solid product obtained was sufficiently washed with purified heptane, 3 1 of n-heptane, 160 g of diisoamyl ether and 350 g of titanium tetrachloride were further added. Then, the polymerization was carried out at 65 0 C for 1 hour. Further, the reaction mixture was sufficiently washed with heptane again, dried under reduced pressure to obtain a solid catalyst component.

Preparation of Pre-Polymerization Catalyst A stainless autoclave (inner volume: about 10 liters) was charged with 5 1 of n-heptane, 14 g of diethylaluminum chloride and 10 g of the above-mentioned solid catalyst component. Then, hydrogen was introduced to raise a total pressure to 3 Kg/cm 2 G, and further propylene was introduced to raise a total pressure to 8 Kg/cm 2 Then, the reaction was carried out for 5 minutes. After the reaction system was vacuumed, the solid product was filtered off, and dried under reduced pressure to obtain a pre-polymerization catalyst.

Propylene Polymerization A 10-liter stainless polymerization reactor equipped with a turbine type stirring wing, which was purged with nitrogen gas, was charged with 4.0 1 of n-hexane, then 0.4 g of diethylaluminum monochloride, 0.4 g of the pre-polymerization catalyst obtained as above and 0.44 g of methyl p-toluate.

54v Further, 4.0 N1 of hydrogen was added. Then, the temperature was raised to 70 0 C and propylene was supplied to raise a total pressure to 10 Kg/cm 2 G. After the polymerization was continued at 70 0 C under a pressure of 10 Kg/cm 2 G for 4 hours, 1.0 1 of methanol was supplied and the temperature was raised *o 800C.

After 30 minutes, 4.0 g of aqueous 20% NaCI solution were added and the mixture was stirred for 20 minutes. Further, after 2.0 1 of pure water were added, the remaining propylene was removed.

After the aqueous phase was withdrawn and 2.0 1 of pure water were added to wash the reaction product with water by stirring for 10 minutes. The aqueous phase was withdrawn and further the polypropylene-n-hexane slurry was withdrawn. Then, the reaction product was filtered off, and dried to obtain polypro:ylene powders.

Comparative Example 16 The polymerization was carried out in the same manner as in Comparative Example 15 to obtain polypropylene powders, except that the amount of hydrogen introduced was changed to 4.4 N1 in the propylene polymerization Comparative Example 17 Preparation of Solid Catalyst Component: A solid catalyst component was obtained in the same manner as in Example i.

Propylene Polymerization: The polymerization was carried out in the same manner as in Example 14 to obtain propylene powders, except that the solid catalyst component obtained as above was used.

Comparative Example 18 The polymerization was carried out in the same manner as in Comparative Example 17 to obtain polypropylene powders, 1.

1~ i except that the polymerization temperature was changed to 60 0 C in the propylene polymerization Using the polypropylene based resins obtained in the above Examples 14 to 16 and Comparative Examples 15 to 18, the pentad fraction (mmmm%), the main elution peak position (Tmax) (OC) and the peak half value width measured by the temperature raising separation method and the melt index (MI) (g/10 min.) were measured in accordance with the above-mentioned measurement methods and measurement conditions, respectively. The results are as shown in Table Further, samples for measurement were prepared in the same manner as in Example i, and the physical properties thereof were measured.

The physical properties measured included tensile elasticity (Kg/cm 2 stress at yielding point (Kg/cm 2 crystallization temperature (oC) and melt temperature (OC) measured by the differential thermometer (DSC), and thermal deformation temperature (load flexture temperature) (HDT) (OC).

The results are as shown in Table 5. In addition, each of the physical properties was evaluated in accordance with the following methods.

Tensile Elasticity The tensile elasticity was measured in the same manner as in Example 1.

Stress At Yielding Point The stress at yielding point was measured in accordance with JIS-K7113.

Crystallization Temperature The crystallization temperature was evaluated by measuring crystallization peak when a press specimen was heated 56 to 220 0 C and kept at the same temperature for 3 minutes and then cooled at a heat down rate of 10 0 C/min.

Melt Temperature The melt temperature was evaluated by measuring melt peak when a press specimen was heated from 50 0 C at a heat up rate of Heat Deformation Temperature (HDT) The heat deformation temperature was measured in the same manner as in Example 1.

57 Table Example Comparative Example 14 15 16 15 16 17 18 mmmm Fraction 96.8 97.0 97.8 98.2 98.0 97.5 95.5 o- 3.2 3.0 3.1 3.6 3.9 3.6 3.6 Tmax 118.3 119.1 118.9 117.6 118.2 118.1 117.5 MI (g/lOmin) 9.9 12.0 50.2 7.1 12.0 15.2 14.3 Tensile Elasticity (Kg/cm 2 22000 23100 24300 18600 19600 19900 17700 Stress At Yielding Point (Kg/cm 2 401 400 412 340 358 375 329 D SC (Sample) Crystallization Temperature 119.8 120.4 120.7 116.6 116.0 117.7 116.0 Melt Temperature 163.0 163.6 162.1 158.7 159.0 159.5 158.1 HDT 127 128 133 112 118 118 105 Example 17 Preparation of Solid Product A solid product was obtained in the same manner as in Example 1. The reaction solution containing the solid product was dried under reduced pressure to obtain a solid product The solid product obtained had a sphericity of 1.20 and a particle size distribution index of 1.8.

Preparation of Solid Catalyst Component: A solid catalyst component was obtained in the same manner as in Example 1.

Propylene Polymerization: A styrene steel-made autoclave (inner volume: about liters) was charged with 30 g of polypropylene powders, sufficiently purged with nitrogen gas, and then charged with mmol of triethylaluminum, 0.5 mmol of diphenyldimethoxysilane and 0.01 mmol of the above-mentioned solid catalyst component in terms of titanium atom. After 0.7 Kg/cm 2 G of hydrogen and 27.3 Kg/cm 2 G of propylene were introduced into the reaction system, the polymerization was carried out under a total pressure of 28.0 Kg/cm 2 at 70 0 C for 2 hour, to obtain a propylene homopolymer.

Example 18 The polymerization was carried out in the same manner as in Example 17 to obtain a propylene homopolymer, except that 0.3 mmol of cyclohexylmethyldimethoxysilane were used instead of diphenyldimethoxysilane in the propylene polymerization.

Example 19 The polymerization was carried out in the same manner as in Example 17 to obtain a propylene homopolymer, except that the amount of hydrogen introduced was increased to 2.0 Kg/cm 2 in the propylene polymerization Comparative Examples 19 I 59 hY A stainless autoclave (inner volume: 10 liters) was charged with 5 1 of purified heptane, 5 ml of diethylaluminum chloride (DEAC) and 0.7 g of TiC13 catalyst (Type 01: Manufactured by Solbey Co.).

After a prescribed amount of hydrogen and propylene were introduced, the polymerization was carried out at 70 0 C under a total pressure of 8.0 Kg/cm 2 G for 90 minutes. Thereafter, the reaction gas was purged from the reaction system, and 50 ml of n-butyl alcohol were added. After the reaction mixture was heated and stirred at the same temperature for 30 minutes, a polymer in the slurry was filtered off, and dried under reduced pressure, to obtain a propylene homopolymer.

Comparative Example Preparation of Solid Catalyst Component: A solid catalyst component was obtained in the same manner as in Example 1.

Propylene Polymerization: The polymerization was carried out in the same manner as in Example 17 to obtain propylene powders, except that the solid catalyst component obtained as above was used.

Comparative Example 21 Preparation of Solid Catalyst Component: A solid catalyst component was obtained in the same manner as in Comparative Example Propylene Polymerization: The polymerization was carried out in the same manner as in Example 17. However, first the polymerization was carried out under conditions where the hydrogen/propylene ratio was adjusted to provide an intrinsic viscosity of 5.0. Then, a whole amount of the reaction gas was purged from the reaction system and the polymerization was again carried out under conditions where the reaction gas formulation was adjusted to provide an 60 intrinsic viscosity of 1.0 and the former stage/latter stage reaction ratio of 55%/45% was obtained, to give final propylene powders.

Comparative Example 22 Preparation of Solid Catalyst Component: A glass reactor equipped with a stirrer, which was sufficiently purged with nitrogen gas, was charged with 600 ml of n-heptane, 0.5 mol of diethylaluminum chloride and 1.2 mol of diisoamyl ether. Then, the reaction was carried out at room temperature for 5 minutes.

A reactor separately provided was charged with 4.0 mol of titanium tetrachloride. After the above reaction solution was added dropwise over a period of 180 minutes, the reaction was carried out at room temperature for 80 minutes. Further, reaction mixture was heated to 75 0 C and stirred under heat conditions for 1 hour.

After the solid product obtained was sufficiently washed with purified heptane, 3 1 of n-heptane, 160 g of diisoamyl ether and 350 g of titanium tetrachloride were further added. Then, the polymerization was carried out at 65 0 C for 1 hour. Further, the reaction mixture was sufficiently washed with heptane again, dried under reduced pressure to obtain a solid catalyst component.

Preparation of Pre-Polymerization Catalyst A stainless autoclave (inner volume: about 10 liters) was charged with 5 1 of n-heptane, 14 g of diethylaluminum chloride and 10 g of the above-mentioned solid catalyst component. Then, hydrogen was introduced to raise a total pressure to 3 Kg/cm 2 G, and further propylene was introduced to raise a total pressure at 8 Kg/cm 2 Then, the reaction was carried out for 5 minutes. After the reaction system was vacuumed, the solid product was filtered off, and dried under reduced pressure to obtain a pre-polymerization catalyst.

61 Propylene Polymerization A stainless autoclave (inner volume: 10 liters) was charged with 4 1 of purified heptane, then 0.4 g of diethylaluminum chloride, 0.4 g of the pre-polymerization catalyst obtained as above and 0.44 g of methyl p-toluate (Manufactured by Inoue Kohryo). Thereafter, in the same manner as in Comparative Example 3, the polymerization was carried out in two stages so as to adjust a ratio of a polymer having an intrinsic viscosity of 5.0 to a polymer having an intrinsic viscosity of 1.0, to 55/45.

The obtained polypropylene slurry was incorporated with ml of n-butyl alcohol, heated to 700C and stirred at the same temperature for 30 minutes, filtered off, and dried under reduced pressure, to obtain a propylene homopolymer.

Using the polypropylene based resins obtained in the above Examples 17 to 19 and Comparative Examples 19 to 22, the pentad fraction (mmmm%), the main elution peak position (Tmax) (OC) and the peak half value width measured by the temperature raising separation method and the melt index (MI) (g/10 min.) were measured in accordance with the above-mentioned measurement methods and measurement conditions, respectively. The melt tension was measured in accordance with the method described below under the conditions described below. The results are as shown in Table 6.

Melt Tension: The melt tension was measured using a melt tension tester (Manufactured by Toyo Seiki). In the measurement, a specimen was melted at 230 0 C and extruded from a nozzle (hole diameter: 2.10 mm; length 8.00 mm: cylinder inner diameter: 9.55 mm) at a fixed rate (piston down speed: 10 mm/min.) and then a melted strand extruded through a road cell was withdrawn by a roller (outer diameter: 5.0 cm) rotated at a fixed rate (20 rpm).

62 A stress generated in the above procedure was measured as the melt tension.

Further, samples for measurement were prepared in the same manner as in Example 1, and the physical properties thereof were measured.

The physical properties measured included tensile elasticity (Kg/cm 2 and thermal deformation temperature (load flexure temperature (HDT) The results are as shown in Table 6. In addition, each of the physical properties was evaluated in the same manner as in Exaimple 1.

63 y Ta bl1e 6 Example )(Comparative Example) 17 18 19 19 20 21 22 mmmm Fraction 96.9 97.0 97.0 95.7 98.0 97.8 96.6 a- 3.8 3.6 3.4 4.2 4.2 5.8 5.1 Tmax 0 C) 118.3 118.8 118.6 113.5 115.3 115.1 117.5 MI (g/l.0min) 0.49 0.55 2. 00 0.69 1.20 0.62 0.55 Tensile Elasticity (Kg/cm 2 18800 19000 18900 14300 17100 16000 15800 Meit Tension g 4.7 4.9 4.0 3.2 2.7 5.1 4.9 H DT (OC 119 119 121 98 110 106 102 Industrial Applicability As mentioned above, the polypropylene and its composition according to the present invention are useful in the fields of several industrial materials, particularly in the fields of automotive, electrical appliances and the like, which require high stiffness and good heat resistance.

65

Claims (9)

1. A polypropylene-based polymer resin comprising: a propylene polymer having a content of alpha-olefin other than propylene of from zero to not more than 4 mole percent, (ii) a pentad fraction (mmmm fraction) measured by 13C-NMR of at least 96.0 percent, (iii) a main elution fraction peak position of at least 117.0°C and a peak half value width of less than 4.0, these values being measured by the temperature raising separation method, and (iv) an intrinsic viscosity of at least 0.5 dl/g, but not more than 5.0 dl/g; and, a rubber content measured by pulse NMR of at least 8 percent.

2. A polypropylene-based polymer resin according to claim 1, wherein the propylene copolymer or homopolymer has a main elution fraction peak half value width of less than 3.4.

3. A polypropylene-based polymer resin according to claim 1, wherein the propylene copolymer or homopolymer has an intrinsic viscosity of not more than 2.0 dl/g. e

4. A polypropylene-based polymer resin according to claim 1, wherein the propylene polymer has a rubber content measured by pulse NMR of at least percent.

5. A polypropylene-based polymer resin according to claim 2, including a second propylene copolymer having an intrinsic viscosity of not less than dl/g. 67

6. A polypropylene-based polymer resin according to claim 2, wherein the propylene copolymer or homopolymer has a molecular weight distribution index (PDi) of not more than 15, the molecular weight distribution index being calculated in accordance with the following equation: PDi=W2/10W1 wherein W1 is an angle frequency when storage elasticity measured by the melt-viscosity method is 2 x 105 dyn/cm2; and W2 is an angle frequency when the storage elasticity is 2 x 103 dyn/cm2.

7. A polypropylene-based polymer resin according to claim 2, wherein the propylene homopolymer has a melt index of at least 0.01 g/10 min. but not more than 200 g/10 min.

8. A polypropylene-based polymer resin according to claims 1 or 6, wherein the propylene homopolymer has a melt index of at least 0.01 g/10 min. but not more than 3.0 min, and (ii) a melt tension satisfying the following equation: -5.2 log MI wherein T is the melt tension measured at 2300C; and MI is the melt index.

9. A polypropylene-based polymer resin according to any one of claims 1 to 8, wherein the propylene polymer is a homopolym'ier which is homopolymerized in one step. DATED this 25th day of January, 1994. IDEMITSU PETROCHEMICAL CO., LTD. WATERMARK PATENT TRADEMARK ATTORNEYS o THE ATRIUM 290 BURWOOD ROAD HAWTHORN VICTORIA 3122 AUSTRALIA ED doc 044 AU2 2WP IAS:MED:JL doc 044 AU2166692.WPC ABSTRACT Polypropylene-based polymer resins and compositions comprising the resin having extremely high stiffness, heat resistance and impact strength, with these properties being well balanced, are provided. The polypropylene based resins are characterized by comprising: a propylene polymer having a content of alpha-olefin other than propylene of from zero to not more than 4 mole percent, (ii) a pentad fraction (mmmm fraction) measured by 13C-NMR of at least 96.0 percent, (iii) a main elution fraction peak position of at least 117.0 0 C and a peak half value width of less than 4.0, these values being measured by the temperature raising separation method, and (iv) an intrinsic viscosity of at least 0.5 dl/g, but not more than 5.0 dl/g; and, a rubber content measured by pulse NMR of at least 8 percent. *o~ o* ogo